Apparatus for making drop-forged steel car wheels



C. H. JERNBERG.

APPARATUS FOR MAKING DROP FORGED STEEL CAR WHEELS.-

APPLICATION man Nov. 1,5. 1920.

1,408,702. Patented Mar. 92.2.

3 SHEETS-S EE el Wf/l C. R. JERNBERG. Y APPARATS FOR MAKING DROP FORGED STEEL CAR WHEELS.

A P P L l C A T 0 N F l L E D N O V l l 5 i 9 2 0.

1,408,702. Patented Mar. 7,1922.v s SSSSSSS SHEET 2.

l W /I l y j @l@ @fl H C. R. JERNBERG.

APPARATUS FOR MAKING DROP FORGED STEEL CAR WHEELS.

APPLICATION FILED Nov. I5, 1920.

1 ,408,702, Patented Mar. 7, 1922.

3 SHEETS-SHEET 3.

UNITED STATES PATENT oFFlcE.

CARL RICHARD 'JERNBERQ OF CHICAGO, ILLINOIS, VASSIGEN'OR T0 STANDARD FORG-INGS COMPANY, 0F CHICAGO, ILLINOIS, A CORPORATION OF ILLI- NOIS.

APPARATUS FOR MAKING DROP-FORGED STEEL CAR WHEELS.

iaosyros.

Specification of Letters Patent.

Patented Mar. *7, 1922.

Original application filed September 4, 1919, Serial No. 321,597. Divided and this application filed November 15, 1920.

To all whom t may concern:

Be it known that I, CARL RICHARD JERN- Bene, a citizen of the United States, residing at Chicago, in the county of Cook and State of Illinois, have invented certain new and useful Improvements in Apparatus for Making Drop-Forged Steel Car Wheels, of which the following is a specification, reference being had to the accompanying drawings, and to the reference characters marked thereon, which form a part of this specification. I

This invention relates to apparatus for making forged steel car wheels, and more particularly relates to the roughing out and finishing dies used in the forging operations.

This application is a division of my former application, Serial No. 321,597, filed September 4, 19.19. The advantages of the apparatus, and mode of operation thereof will be fully understood as I proceed with my specification.

In the drawings: 4

Fig. l illustrates in a perspective view, an ingot or blank from which the steel car wheel is to be forged by my improved apparatus.

Fig. 2 is a central, vertical, sectional View of'a steel car wheel produced by the use of my invention.

Fig. 3 is a plan or face view of they upper die used in the first or roughing out operation. I Y

' Fig.4 is a plan or face view of the upper die used in the second or finishing operation.

Fig. 5 vis a plan or top view ofthe lower die used in the first or roughing out op* eration.

Fig. 6 is a side elevation, partly in section, of the upper and lower dies of Figs.

3 and 5, in juxtaposition, without the blank.

Fig. 7 is a plan or face view of the lower die used in the second operation.

Fig.l 8 is a vertical elevation, partly in section, of the upper and lower dies of Figs. 4 and 7, in juxtaposition.

In said drawings, A will represent the blank or billet as a whole, substantially rectangular in shape and of dimensions less than the diameter of the proposed wheel, and having a thickness slightly in excess of serial No. 424,281.

the width of the rim of the proposed wheel.l

Where, for example, I desire to make a car Wheel the diameter of which at the tread is 33%,1 inches, the thickness of'` the rim about 5%; inches, having a flange projecting from the tread of 1% inch, and having a hub substantially 10 inches in diameter and 7 inches deep, I find that I can'use a blank or billet of steel 6% inches thick by22 inches square, weighing approximately`882 pounds. When .such a blank is subjected to the drop forging operation by the apparatus herein illustrated and claimed, a wheel of the desired dimensions will be produced.

These figures are given by way of illustration and not as limitations; inasmuch as it will be manifest that blanks or billets of other dimensions may be used.

The letter B indicates as a whole a drop forged car wheel made from the billet or blank A by the use of my apparatus. Referring now more particularly to Figs. 3, 5 and 6, C will represent the upper die as a whole, D the lower die as a whole, E a suitable support or part of a drop for e adapted to sustain the lower die D. Tile support E is preferably provided on its top surface, upon which the die D rests, with a circular recess l, in which is located one or' more circular springs 2, 2. In the upper portion of the recess l and resting upon the top of thek spring or springs 2, 2, is a circular boss 3 integral with the die D. The length of the springs is such as' to cause the boss 3 to stand somewhat out of the recess 1, normally, thus slightly raising the lower surface of the die D above the sup-V portE, and affording the familiar cushioning action desirable in drop forge operations. The upper part of the recess'l acts,

also as a bearing for the stud 3 so that the lower die D may be rotated about the longitudinal vertical axis of the stud 3. This rotation may be accomplished by any suitable Ineans, but I have illustrated as one means a plurality of projections or sprocket teeth 4: locatedV at equal distances apart around the periphery of the main or body portion of the lower die D. These sprocket teeth are adapted to be engaged by a sprocket chain actuated from any suitable source of power (said sprocket chain and means for actuating it not being shown),

able upstanding flange member 5, adapted for attachment to theV reciprocating hammer head (not shown) of any suitable hammer.

The proximate Viaces of the upper and lowerV dies C, D, are complementally recessed 1n the manner and Jfor the purposes herein'-Y after described. It will be noted, however,` that the vlower ldie 5 is circular 4and of a size u Viiifeamess ofthe 'ultimate' diameter of the @n when, while the. upper die ro, is rela tively long` r and narrow,v with arcuate"v r'ec'es'ses andpfrojections., v y

Referring ow `more particularly tothe lower die (Figs. 5 and 6) it will be seenv that circumferential recess 6 is cut inits face y13 toa depth substantially equalV to the thickness of the rim bjof the wheelv B, Said recess 6 has a slightly tapered outer wall 7 terminatingfin asomewhat rounded iilletfS. Thediameter of the recess 6 is sub# stantially the saine as that ofthe circumferential diametero tlietread oit-he finished wheel. Thel inclined inner, wall9 of this recess entends upwardlyand inwardly from the bottom `1'0 and terminates in a horizontal surface 12 lying in Ya plan'elsomewh'at below the top surface 13 oi' the die D. vAn` annular Vrecessie is cut in the face of the surface 12, so' that its bottom 15 is in substantially the, same horizontal plane as the b'ot.

tomi() ci" the recess 6'.` The two side walls of the recess 14; flare outwardly somewhat from the bottom 15 toward the surface 12.

This annular recess 14 forms a centrally,

projecting tapered boss 16, the top edge of which may be very slightly rounded; l The upper die (l is of a length slightly in eiicess of the diameter of Vthe recess 6, as cle'arl illustrated in Fig. 6. Its width is consic erablyless than thediameter 'of said-v recess 6, as clearly shown in` Fig. 3. Longietudinally of the iacel orsaid die isa rib 18, narrower than the widtlifof theV face 17 v This rib 18y isprovidedl with la centrallylo- Y transversely `of the rib 18.

cesses 2O and the extreme end of the rib 18,

cated, outwardly projecting taperedboss 19; the 4taper andthe diameter of this boss correspending with the taper and diameter'of the boss 160i the lower die, as clearly shown in Fig'. 6., Surrounding the boss 19. are arcuate or segmental recesses 20, one on each side of the boss 19, said'arcuate recesses extending Between the resai'd rib is` curved Vor, rounded as indicated by the surf-aces 21; said rounded Vsurface 21 merging into the flat or horizontalsurfaces 22, 22, one kat each end of `therribl.. f

l It will be seen by reference to Fig. 3 that the ,transverse dimension `of the contacting suriacesoi' the upper die C are substantially` the same or only slightly greater in width for peaning hammer in the drop forging action.- In use, the dies'C and D have the blank A placed between them, the blank rest- -Y ing onl the lower 'die D, andas the latter revolves upon its central vertical axis, the upperdie C is given a reciprocating action bythe drop forge or hammer and repeatedly strikesthe blank A, but at a dierent'place each time, since the blank A rotates with the lower die D. This produces the necessaryY roughing out oi the blank A and reduces itfto ashape or form `whicliinV crosssectional Varea would approiiinate the space betweenwtlie vdies ,C and YD illustrated in Fig. 6. That is to say, theblank- A would bel caused to approiimate theshape of they wheelvfB by having' a central hub and an outer lan'e roughed out, connected by a cene tial or horizontally disposed disc' or web; the hub having l a A central recess punched therein from both vside`s,--the twonot', however, communicating with each other.l *Y

Referring nowto Fis. 4,7 'and 8, F is a lower die as a whole, '(1 is theJ upper die as a whole; the lower die resting upon the support EgThe' lower die F is also provided with sprocket teeth 4;. The die F differs from the die D only `in the contour orlsh'ape of its upper face. It will be seen thatit is provided with two concentric recesses 23, 2&1. The inner recess 24 has tapered walls, the outer oneterminating in a curve `as indicated at 25. `This centrally located recess 211 does not extend as deeply into the die as does the recess 23, as clearlyindicated in Fig. 8, and forms in the finished product one side c of the hub Z of the wheel B. The outer wall .of the recess 23 forms the tread of the wheel and said wall terminates at its vupper end where it joins the surface 26 of the. die F, in a suitably curved orr'ecessed part27, which part in connection with a complemental part on the upper die Gr 'will form in the iinished wheel the flange e. The inner wall 28 of Ath'elrecess 23 is given a suitable curve 29 until it meets Athe curve 25 of the recess 24. This portion` 29,-together `withgthe complemental Apartof the upper die'G,"forms one side f of the web of the car wheel B, connecting its hub Z ywith the rim c. j The curved or recessed part27 is of the shape and one-halter` the thickness oit-the flange e of the iinished wheel B. 30 is the central hub or boss projecting upwardly from the bottom of the inner annulan recess 24. A

Referring now more particularly to Figs. 4 and 8, the upper die G comprises areeextending and upwardly directed head 32 by which it may be secured in any suitable or convenient manner to the reciprocating head or part of the drop forge. On its face, the upper die Gr is provided with a projecting tapered hub or boss 33,.corresponding with and substantially of the same dimension and configuration as the hub or boss 30 of the lower die F. 0n either side of this hub are segmental ribs g each of which is provided with suitable recesses and projections corresponding with and complemental to the lower die. F or example, the recess 34 corresponds with the recess 2a of the lower die and the recess 35 corresponds with the recess 23 of the lower die. The rounded parts 36 and 37 correspond with the rounded portions 25 and 28 of the lower die, while the undulating surface 38 of the upper die Gr is complemental to the undulating surface 29 of the lower die. It will be observed that the recesses and projections just described, on the segments g, extend in a direction transversely of the upper die G or more properly stated, are formed upon the arc of a circle drawn about the center of the boss 33.

Vhen the blank is submitted to the forging action of the dies, F and G, the lower die being constantly rotated and the upper die Gr being given the familiar drop forging reciprocating action, said blank will presently assume a shape corresponding to the finished product, as shown inFig. 2. 1t will be noted that the upper die Gr will not impinge upon the blank at the same spot twice in succession, owing to the rotation of the lower die F during the forging operation. llhen the finishing operation on the blank by means of the dies F and G has been cornpleted, the blank will be in the shape and configuration shown in Fig. 2, with these eX- ceptions: first, there may project from the flange e a very slight burr or fin, and there will be found in the hub c a central transverse web indicated by the dotted line at fz. The rest of the wheel will be in finished shape. The finishing off will consist in removing the burr or fin, if any, from the flange e, and in punching out the web L and boring the hub to a proper diameter to fit upon a car aXle. So far as the forging operation is concerned, the diameter of the wheel, the thickness of the tread, the size and shape of the hub and the curved web connecting the hub and the tread and the size and shape of the flange on the tread, are all completed and finished by the use of the dies l", (l, and require no further machining.

1t will be noted that a concentric. groove Ll() is provided in the face of the lower die l?, to take care of any surplus metal in the fin or burr that may extend from the flange of the completed wheel.

1 am aware that it has been heretofore a 1 have found by repeated experiments that i the narrow die (upper) shown in Fig. 3, produces the best results; that the metal more readily conforms to the proper' shape and is molded and welded and stretched and pushed into proper position without lacerating, so to speak, the grain or fibre of the metal; and that the finished product produced from the dies herein illustrated and described is more perfect and durable in use.

I find also that the cost of the upper dies, Figs. 3 and l, is considerably less than the cost of the dies required in hydraulic pressing operations, and that the time required to manufacture the car wheel such as shown in F ig. 2 by the use of my improved dies is considerably less than that required in the pressing operations.

It follows, therefore, that by the use of my dies the cost of manufacture of steel car wheels is greatly reduced.

lVhile l have shown and described in detail, certain specific shapes and forms of recesses and grooves in the die surfaces, it will be understood that modifications of these shapes and forms may be made to con respond with the contour of the car wheel to be fabricated. 1 therefore desire my invention not to be limited. to the specific form herein illustrated, except as hereinafter set forth in the appended claims.

l claim as my invention:

l. An apparatus for roughing out the blank in the forging of steel car wheels, comprising a pair of roughing out dies, the lower die having an annular recess in its upper face, the outer side wall ofwhich is substantially the diameter of the tread of the wheel, a central, circular boss raised up from the bottom of said recess and of a height less than the depth of the recess, and an annular web forming projection intermediate said boss and the recess side wall, the upper die having an operating surface of a length slightly greater and a width appreciably narrower than the diameter of the annular recess in the lower die, and provided with complemental projections and recesses to cooperate with the lower die, means for operatively attaching said lower die to a rotatable element and means for operatively attaching the upper die to a reciprocating element.

2. An apparatus for finishing the roughed out blank in the forging of steel car wheels,

comprising a pair of inishing clies,the lower die having an'ainiularV recess in its upper below the face of the die, an annular circum ferentiel recess surrounding said boss, theV bottom of said recess being parallel Withrthe ace of the die7 said inner recess being of less depth than the first mentioned or outer recess, and a Web forming annular rib Vintermediate the said two recesses; the upper Clie being of a length slightly greater than and of a Width appreciably less than the diameter of the groove Vin the face of the lower die,v

and having c-omplemental projections and recesses, means Jfor operativelyV attaching the lowerdie to a'rotatng element and means `for operatively attaching the upper die to areciprocating element.

- VIntestimony that I claim the foregoing as my invention I aiiix my signature in the presence of two witnesses, this 12th day of November, 1920. y

" CARL RICHARD JERNBERG.

lfVitnesses: Y

4'IX/irma E. BROWN, v B; L. MAGGREGOR. 

